Portable medical waste processing system &amp; method

ABSTRACT

A portable medical waste processing system and method includes a processing device and a medical waste container. The processing device has an enclosure with a housing and a lid, with at least one heater, a control system, a filtration system and a cooling system inside the enclosure. The control system regulates the temperature of the heater and time of the process cycle. The filtration system prevents noxious odors emanating from the container during the process cycle. The cooling system prevents heat build-up inside the enclosure and also ensures that the sides of the enclosure do not exceed harmful temperatures. The portable medical waste processing system melts syringes and sterilize needles, lancets and infectious waste that are placed in the medical waste container that is inserted into the heater. The system identifies and responses to short and long term power interruptions.

This application claims the benefit under 35 U.S.C. §119(e) of the U.S. provisional patent application No. 61/503,649 filed Jul. 1, 2011, for the matter disclosed therein.

TECHNICAL FIELD

The present invention relates to the medical waste and more particularly to systems and a method for the destruction of disposable medical devices and sterilization of infectious medical waste.

BACKGROUND ART

Infectious Waste is defined as any waste that may contain infectious material such as body fluids, blood and any disposable devices, such as needles, syringes or scalpel blades, that may have come in contact with these elements. Sharps are any device or object used to puncture or lacerate the skin, and include needles, syringes, lancets and scalpel blades.

Various known systems for the safe management and disposal of infection waste and sharps provide infectious waste sterilization and sharps destruction. These systems make the sharps safe for disposal. Some of these systems melt a syringe and needle into a sterile plastic puck and some destroy the needle or otherwise render the needle harmless. Generally, these prior known systems that melt and sterilize sharps and infectious waste are cost prohibitive, heavy, bulky and are not very portable.

DISCLOSURE OF THE INVENTION

A portable medical waste processing system includes a processing device having an enclosure with a housing and lid, at least one cylindrical heater inside the housing, a filtration system in the lid, a control system in the housing and a cooling system in the housing, and a medical waste container for each cylindrical heater. Needles, syringes, lancets and other sharps are placed inside the medical waste container and the medical waste container is placed inside the cylindrical heater. The control system has an interlock that assures that the lid is closed and that prevents opening of the lid during operation of the processing device, and a container sensor that assures that a medical waste container is in the cylindrical heater before operation of the processing device. The processing device has a bill acceptor and/or credit card acceptor to be used in a vending application, a DC-AC Power Inverter for operation from a DC power supply source such as a DC battery or a Solar Panel, and a barcode reader for reading barcodes on medical waste containers. The method includes heating the medical waste container for a selected time period at a selected temperature, detecting a power interruption, identifying the power interruption as short-term or long-term, and reinitiating the heating for the entire time period after a long-term power interruption.

BRIEF DESCRIPTION OF THE DRAWINGS

Details of this invention are described in connection with the accompanying drawings that bear similar reference numerals in which:

FIG. 1 is a cutaway, side elevation view of a portable medical waste processing system embodying features of the present invention.

FIG. 2 is a cutaway, back elevation view of the processing device of the system of FIG. 1.

FIG. 3 is front perspective view of a medical waste container of the system of FIG. 1.

FIG. 4 is a cutaway, side elevation view of the portable medical waste processing system of FIG. 1 with a processing device having two cylindrical heaters.

FIG. 5 is a top plan view of the processing device of FIG. 4 with the lid removed.

FIG. 6 is a front elevation view of the processing device of the system of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 and 2, a portable medical waste processing system 10, embodying features of the present invention, includes a processing device 12 and a medical waste container 14. The processing device 12 includes an enclosure 16 having a box shaped housing 17 with an open top end 18, and a lid 19 that covers the open top end 18. The housing 17 has a front panel 20. A cylindrical heater 21 mounts in the enclosure 16 and has a cylindrical interior cavity 23 with a lower closed end 24 and a spaced, upper open end 25. A thick cylindrical piece of insulation surrounds the cylindrical heater 21 to contain the heat and keep the remaining enclosure 16 from overheating. By way of example, the heater 21 can be an aluminum cylinder with an electric band heater around the cylinder and/or with a plate heater at the lower closed end 24.

A filtration system 27 mounts in the lid 19 of the enclosure 16, above the open end 25 of the interior cavity 23 of the heater 21. The filtration system 27 has a replaceable carbon cartridge 28. The processing device 12 includes a cooling system 30 having at least one fan 31. The fan 31 shown is a two speed fan with a speed tachometer and is mounted to the bottom of the housing 17 of the enclosure 16.

The processing device 12 has a control system 34 with a programmable controller 35 that has non-volatile memory 36, a real-time clock 40 and a battery 43 to power the clock 40 during power interruptions. The clock 40 and battery 43 provide a means for tracking the current time. Other means for tracking the current time can be used, such as a communications link to an atomic clock, a cellular network or an internet clock. By way of example, and not as a limitation, the controller 35 can include a microprocessor. The controller 35 connects to the heater 21, and to the fan 31 of the cooling system 30. The controller 35 activates the fan 31, and the fan 31 sends fan speed feedback to the controller 35.

The control system 34 also includes an electrically activated lid latch, shown as lid latching solenoid 37, an interlock 38, a container sensor 39, a temperature sensor, shown as a thermocouple 41 and a thermal cutoff 42, all of which connect to the controller 35. The lid latching solenoid 37 mounts on the housing 17 of the enclosure 16, and secures the lid 18 when activated. The interlock 38 connects to the lid latching solenoid 37, indicating to the controller 35 when the lid 18 is secured. The container sensor 39 mounts on the lid 18, over the open end 25 of the interior cavity 23 of the heater 21, and the thermocouple 41 and the thermal cutoff 42 each mount on the side of the heater 21.

A bill acceptor 44 and a credit card acceptor 45 mount on the exterior of housing 17 and connect to the controller 35. A DC to AC inverter 46 mounts in the housing 17 and also connects to the controller 35. A barcode reader 47 mounts on the exterior of housing 17 and connects to the controller 35.

The medical waste container 14 shown in FIG. 3 has a hollow cylindrical body 48 with an open end 49, and a cap 50 that fits over the open end 49. The medical waste container 14 is made of metal or other material that will not melt during the heating cycle of the processing device 12. Preferably, the medical waste container 14 is made of aluminum. The medical waste container 14 has a barcode 51 on the exterior surface of the body 48. The medical waste container 14 is sized and shaped to fit into the cavity 23 in the heater 21. The container sensor 39 indicates to the controller 35 whether a medical waste container 14 is in the cavity 23.

Referring again to FIGS. 1 and 2, the controller 35 regulates the temperature of the heater 21 to a selected first temperature for a selected time period. Preferably, the medical waste container 14 is heated to between about 350° F. and 400° F., and more preferably about 370° F., for at least about 75 minutes. The non-volatile memory 36 stores data, including but not limited to the date, time, temperature, process ID, and the barcode 51 on the medical waste container 14, during operation of the processing device 12. The interlock 38 and the container sensor 39 prevent misuse of the processing device 12 during a heating cycle. After the medical waste container 14 is placed into the cavity 23 in the heater 21 and the process is initiated, the lid 19 is secured by the latching solenoid 37 to prevent the lid 19 from being opened. The interlock 38 provides feedback to the controller 35 indicating that the lid 19 is secured, thereby allowing the heating cycle to begin.

The container sensor 39 provides feedback to the controller 35, indicating that a medical waste container 14 is in place inside the cavity 23 in the heater 21, allowing the heating cycle to begin. The container sensor 39 also indicates to the controller 35 that the medical waste container 14 fits correctly inside the cavity 23 and is a medical waste container 14 specifically designed for the processing device 12. The fan 31 is activated at low speed by the controller 35 when the heating cycle begins.

The fan 31 is activated at high speed once the heating process has concluded and cools the medical waste container 14 so that the medical waste container 14 can be removed safely. The fan 31 is deactivated once the medical waste container 14 has cooled for removal from the processing device 12. The cooling system 30 regulates the heat and provides cooling to the sides walls of the enclosure 16 and also provides cooling for safe removal of the medical waste container 14. After the heating process has concluded and the medical waste container 14 has cooled to a selected second temperature, the latching solenoid 37 is deactivated so that the lid 19 can be opened. By way of example, the second temperature can be about 120° F.

The heater 21 is capable of reaching high temperatures designed to melt polypropylene and sterilize infectious waste. The thermocouple 41 provides continuous feedback to the controller 35 indicating the temperature of the heater 21. The thermal cutoff 42 provides upper limit temperature protection preventing the heater 21 from reaching excessive temperatures.

The control system 34 can support and control multiple interface types such as GPS, RS-232, USB 2.0, 3,0 802.15.1 Bluetooth, 802.3 Ethernet, 802.11a/b/g/n Wireless Ethernet and 802.15.5 Zigbee. The control system 34 supports multiple types of printers and data storage units such as USB flash drives, hard drive and memory card. Data stored in the non-volatile memory 36, such as but not limited to the date, time, temperature, process ID, and the barcode 51 on the medical waste container 14, can be archived on the data storage units.

The bill acceptor 44 and credit card acceptor 45 allow the processing device 12 to be placed in commercial sites where payment would be required to process a medical waste container 14. The processing device 12 nominally operates on conventional AC power. The inverter 46 allows the processing device 12 to be powered by a DC Voltage Source such as a DC battery or a Solar Panel. The inverter 46 may also be placed outside the processing device 12 as an adjunct device. The inverter 46 converts power from a DC Voltage source to the AC power required to operate the processing device 12.

The medical waste container 14 is heated to a temperature that will melt the contained syringes and sterilize the needles, lancets and infectious waste. The filtration system 27 filters any noxious odors emanating from the container during the heating process. The control system 34 regulates the heater 21 to the selected first temperature for the selected time period of processing designed to melt the syringes and sterilize all material contained within the medical waste container 14. The cooling system 30 prevents heat build-up inside the enclosure 16, cools the medical waste container 14 once the heat process is completed and also ensures that the sides of the enclosure 16 do not exceed harmful temperatures. The barcode reader 47 allows the barcode 51 on the medical waste container 14 to be scanned and stored.

When the processing device 12 is powered up, the controller 35 checks the non-volatile memory 36 to determine whether the last process cycle was completed or interrupted by a power interruption. If the last process cycle was interrupted, the controller 35 determines whether the power interruption was a short-term or a long-term power interruption. For example, a short-term power interruption may be defined as a power interruption of less than ten minutes and a long-term power interruption may be defined as a power interruption equal to or greater than ten minutes. If the power interruption was a short-term power interruption, the medical waste container is heated for the remainder of the time period of the last process cycle. If the power interruption was a long-term power interruption, the medical waste container is heated for the complete time period of a process cycle.

FIGS. 4 and 5 show the portable medical waste processing system 10 with a processing device 52 having two heaters 21. A portable medical waste processing system 10 embodying features of the present invention may have one, two or more heaters 21. The processing device 52 with two heaters 21 can operate with a medical waste container 14 in one or in both heaters 21 during a process cycle.

Referring to FIG. 6, a user interface 54 mounts on the front panel 20 of the housing 17. The user interface connects to the controller 35. The user interface 54 shown includes a display 55, such as an LCD display, and a start button 56. The display 55 can be used to show the current date, time and process id for the current process. The display 55 can also report the heat temperature during the heat cycle as well as the cooling temperature during the cooling cycle. The display 55 can also graphically or through a simple text message report the progress of the process cycle. The display 55 can also guide a user with instructions on how to load the processing device 12 with a medical waste container 14, to begin a process cycle and finally to remove the medical waste container 14. The start button 56 can be a pushbutton or a switch.

Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that changes in details of structure may be made without departing from the spirit thereof. 

1. A portable medical waste processing system, for melting and decontaminating medical waste, comprising: a processing device having an enclosure with a housing and a lid that opens and closes, at least one cylindrical heater in said enclosure and a control system in said enclosure, said heater defining a cylindrical interior cavity with a closed end and a spaced, open end that is covered by said lid when said lid is closed, and said control system including a controller connected to said heater, and a container sensor connected to said controller, said controller regulating said heater at a selected first temperature for a selected time period, and a medical waste container for each said heater, said container being sized and shaped to fit into said interior cavity, said container having a hollow cylindrical body, for receiving said waste, with an open end and a removable cap that fits over said open end, wherein said container sensor indicates to said controller that said medical waste container is in said cavity and is specifically designed for said processing device, whereby medical waste is melted and decontaminated after being heated in said container in said cavity for said time period at said first temperature.
 2. The system as set forth in claim 1 wherein said processing device includes at least two said heaters each connected to said controller.
 3. The system as set forth in claim 1 wherein said control system includes an interlock, an electrically activated lid latch connected to said interlock and said controller, said latch securing said lid in a closed position when activated by said controller and said interlock indicating to said controller when said lid is secured.
 4. The system as set forth in claim 3 wherein said latch is a lid latching solenoid.
 5. The system as set forth in claim 3 wherein said controller activates said latch until said heater has cooled below a selected second temperature, after said controller regulates said heater at said first temperature for said time period.
 6. The system as set forth in claim 5 wherein said second temperature is about 120° F.
 7. The system as set forth in claim 1 wherein said processing device includes a cooling system inside said housing and a filtration system in said lid, said cooling system including a two speed fan mounted in said housing and connected to said controller, said controller activating said fan at a low speed when said time period begins and activating said fan at a high speed when said time period ends.
 8. The system as set forth in claim 7 wherein said fan sends fan speed feedback to said controller.
 9. The system as set forth in claim 1 wherein said controller includes non-volatile memory that continuously stores data including the date, time, temperature, and a process ID, during operation of said processing device.
 10. The system as set forth in claim 9 wherein said controller includes a means for tracking current time, and said controller is programmed to detect a power interruption during operation of said processing device.
 11. The system as set forth in claim 10 wherein said means for tracking current time includes a real-time clock and a battery to power said clock during said power interruption.
 12. The system as set forth in claim 10 wherein said controller is programmed to identify said power interruption as one of a short term power interruption and a long term power interruption, to regulate said heater at said first temperature for the remainder of said time period after a short term power interruption, and to regulate said heater at said first temperature for an entire said time period after a long term power interruption.
 13. The system as set forth in claim 12 wherein said short-term power interruption is less than ten minutes and said long-term power interruption is any longer power interruption.
 14. The system as set forth in claim 9 wherein said processing device includes a barcode reader connected to said controller, said container includes a barcode, and said data stored in said memory includes said barcode of said container in said heater.
 15. The system as set forth in claim 1 wherein said control system supports at least one of a printer and a data storage unit, said data storage unit being selected from the group of a USB flash drive, a hard drive and a memory card.
 16. The system as set forth in claim 1 wherein said control system controls at least one interface selected from the group of GPS, RS-232, USB 2.0, USB 3.0, Bluetooth, Ethernet, IEEE 802.11a/b/g/n Wireless Local Area Network and IEEE 802.15.5 Zigbee.
 17. The system as set forth in claim 1 wherein said processing device includes an inverter that converts power from a DC Voltage source to AC power to operate said processing device.
 18. The system as set forth in claim 1 wherein said processing device includes a bill acceptor and credit card acceptor connected to said controller to allow said processing device to be placed in commercial sites where payment would be required to process a said medical waste container.
 19. The system as set forth in claim 1 wherein said processing device includes a display connected to said controller, said display displaying date, time, process id, temperature and process cycle progress.
 20. The system as set forth in claim 1 wherein said processing device includes a display connected to said controller, said display displaying user instructions.
 21. A portable medical waste processing system, for melting and decontaminating medical waste, comprising: a processing device having an enclosure with a housing and a lid that opens and closes, at least one cylindrical heater in said enclosure and a control system in said enclosure, said heater defining a cylindrical interior cavity with a closed end and a spaced, open end that is covered by said lid when said lid is closed, said control system including a programmable controller connected to said heater, an interlock and a container sensors each connected to said controller, and a lid latching solenoid connected to said interlock and said controller, said solenoid securing said lid in a closed position when activated by said controller and said interlock indicating to said controller when said lid is secured, said controller regulating said heater at a selected first temperature for a selected time period, and activating said latch until said heater has cooled below a selected second temperature, after regulating said heater at said first temperature for said time period, said controller including non-volatile memory that continuously stores data including the date, time, temperature, and a process ID, during operation of said processing device, a real-time clock and a battery to power said clock during a power interruption during operation of said processing device, said controller being programmed to detect said power interruption, and a medical waste container for each said heater, said container being sized and shaped to fit into said interior cavity, said container having a hollow cylindrical body, for receiving said waste, with an open end and a removable cap that fits over said open end, wherein said container sensor indicates to said controller that said medical waste container is in said cavity and is specifically designed for said processing device, whereby waste is melted and decontaminated after being heated in said container in said cavity for said time period at said first temperature.
 22. A method of melting and decontaminating medical waste comprising the steps of: providing a processing device having at least one cylindrical heater with a interior cavity, providing a medical waste container sized and shaped to fit into said interior cavity, placing medical waste in said container, placing said container in said heater, heating said container at a selected first temperature for a selected time period, detecting a power interruption during said time period, identifying said power interruption as one of short term and long term, heating said container at said first temperature for the remainder of said time period after a short term power interruption, and heating said container at said first temperature for an entire said time period after a long term power interruption. 